Method of and mechanism for coating roofing elements



METHOD OF AND MECHANISM FOR COATING ROOFING ELEMENTS l Filea Maoh 22,1927 2 Sheets Sheet Inf/mw.' JWM ZT WW' Novia 19.

Y H. l.. L EvlN l 78 METHOD OF AND ME CHANISM FOR COATING ROOFINGELEMENTS Filed M arch 22, 1927 2 sh eefs sheet l., 'inviti'.

llllllllll nl portion, which is expose Patented Nov. 18, 1930 UNITEDSTATES 'PATENT' OFFICE mmm I.. LEI-TIN, or Passaro, NEw JERSEY,AssIeNoE, BY mEsNE AssIeNMENTs,

To THE PATENT ANI) LICENSING conomTIoN, or BosToN. mssacnUsETTs, a

coaromTIoN or mssAcnUsETTs IIETIIoD or AND TIEcnANIsx- E OB `COATINGROOFING ELEMENTS Applipcation'jhd latch 22, 1927. l Serial No. 177,407.

V This invention relates to a method of making thick butt fabricatedroofing elements which are characterized b having the butt to theweather when laid, completelycovered both on its exposed face andedgeswith a continuous coating of asphalt preferably masked by a.surfacing layer of grit or its equivalent. Roofing elements of this typeare customarily made of material comprising a felted fibrous base whichis comparatively bibulous. This felted material inl sheet form isthoroughly saturated with waterproofing materiall such as lowmelting-point asphalt. The saturated sheet is thereupon coated on bothsides with a layer of relatively high melting-point oxidized asphaltwhich is particularly suited for weather-proofing the roofing materialand preventing the access of moisture to the fibers of the saturatedbase. In order to protect the exposed coating of asphalt which is liableto deterioration by effects of the weather, such as rays of the sun,.which tend to polymerize the asphalt and render it brittle and subjectto cracking, a surfacing la er of comminuted mineral matter'is applic tothe coating on one or both sides of the sheet to mask and protect thecoating from effects of the weather. The finishing layer of mineralmatter also performs other useful functions such as adding to thedecorative effect of the roofing unit and weighting the exposed portionsto counteract tendencies to curl or to be lifted by the action of wind.-v .From sheet roofing material thus prepared, the roofing elements arecustomarily cut out in an desired shapes and are packaged as a finishedarticle for shipment and subsequent use. Such elements, however, haveobjectionable features in that the cut edges along the butt of theelement expose cut ends of fibers to the weather. These cut ends beingunprotected have been found to absorb moisture in wet Y weather and topermit the access of oxygen oi of v ortions of the coating asphalt andminera surfacing. The rate of such deterioration increases progressivelyinasmuch as the further it goes, themore exposed is the roofing elementto the deteriorating effects of.v

the weather.

Another objectionable feature to roofin A elements cut from a sheet ofroofing materia made as described above is that such material iscomparatively thin and when elements cut therefrom are laid upon a roof,the roof as a whole presents a fiat and unsubstantial appearance, whichis not in keeping with such buildings as residences of the better kind.Hence discriminating architects have largely avoided the ordinaryasphalt roofing elements in the construction of the better class ofresidences on account of the unfavorable appearance often presentedthereby,

In order to overcome the objections to the' ordinary roofing elementsout from asphalt coated sheet material, it has been found that ktif suchelements are provided with an additional coating of asphalt over theportion of Y the element which is exposed to the weather when laid,including the butt andl side edges, such an additional coating servesboth tol seal the edges which were previously a vulnerable point of theelement, and also tothicken the visible portion of the element in such away as to give a roof upon which such elements are laid a substantialappearance. This invention relates to a method of and means for applyingsuch an additional coating of asphalt to pre-cut roofing elements whichhave been made as described above, and applying an additional surfacelayer of comminuted mineral matter, such as crushed slate or the like.to the protective asphalt coating thus applied.

According to my inventionLI have devised apparatus for applying in anovel way to roofing elements cut to shape from nished sheet roofingmaterial, an additional coating of molten asphalt over the face andedges of the elements which will be exposed to the weather when laid,surfacing the additional coat with a layer of comminuted mineral`material, andv operating on the elements thus treated to press themineral particles into ion firm engagement with the asphalt coating andat the same time to shape the thickenedv butt portion of the shingle asdesired.

In carrying out my novel method, I arranged pre-cut roofin elements in acontinuous overlapping series, in which each element is partly overlaidby other adjacent elements 1n the series. Preferably the unlappedportion of each element will be substantially the same as the portion ofthe element which will be exposed to the weather whenthe element is laidwith others on a roof. Upon the unlapped face portions and edges of theelements in the series is applied a continuous coating of suitablewaterproofing material such as certain asphalts commonly used for.coating purposes. Grit or the like may be applied to the coating whilestill hot and sticky, and the elements are separated before the coatingsets or hardens.

This method of applying coating to elements in lapped series may be usedto build up butt portions of extra thickness tapering off toward thehead. This may be done by arranging the elements so that only a smallpart of the butt portion of each is unlapped in the series. After thesehave been coated, with or without the addition of grit, the elements maybe separated further and a second coating applied. This may be repeateduntil the Whole portion of each element which will be exposed to theweather when laid is coated, whereupon the elements are separated andfurther treated as hereinafter described. This results in an elementhaving a number of extra coatings at the butt edge extending toward thehead, each such coating except the top one being overlaid by a coatingextending further toward the head of the element.

Various advantageous features of the in- 'l vention will be apparent toone skilled in the art from the disclosure of the invention in thefollowing description and on the drawings of which- Figure 1 representsdiagrammatically a side elevation of an embodiment of my invention.

Figure 2 is a plan view of the same.

Figures 3 and 4' are detail views of la p0rtion of Figure 1, shown on alarger scale.

Figure 5 illustrates the actionof certain elements on the butt portionof the rooting elements.

Figure 6 is a perspective of a roof-ingelement after being passed thoughthe mechanism illustrated in Figure 1.

Figure 7 is a diagrammatic sida elevation of a modiiied form ofapparatus.

Figure 8 is a plan view of the same.

Figures 9 and 10 are detail views of portions of Figure 7, shown onalarger scale.

` Figure 11 is a side elevation of a portion of the mechanismillustrated in Figure 8.

Fi re 12 is a section taken on the line 12-12 of Figure 11.

Referring to Fi ure 1, a series of'rooing elements 2.0 are .fe to themechanism as on a conveyor 21. The elements are placed on this conveyorin' any overlapping relation either by hand or b ,any suitable mechanism(not shown). Pre erably, although not necessarily, the elements may bepre-heated before being s'o arranged and/or the unlapped surfaces may beheated after the elements have been arranged in` overlapping series asby a steam box 22, a blast of hot air or anyv other suitable andconvenient means. From the conveyor 21, the series of elements 20 may betransferred to another conveyor 23 without altering their relativerelation. Inasmuch as roofing elements of the common asphaltic ty e aresomewhat flexible and have a rougii surface due to the surfacing layerof grit, the relative relation between successive elements placed in anoverlapping relation as shown will not easily be disturbed except bypositive means operating for that purpose. As indicated in Figures 3 and4, the elements 20 are overlapped upon each other in such a way thateach element is covered by the next overlying element by approximatelythe same amount and at substantially the same portions thereof as theelement will be overlaid when in place on a roof, so that the uncoveredportion as shown in Figures`3 and 4 represents substantially the portionto be exposed to the weather when the element is laid on a roof. In thisform of the apparatus, the elements are shown as being advanced buttedge iirst, each element being partly overlaid by elements following it.The conveyor 23 which receives the series of elements may be disposedhorizontally if desired, but as shown on the drawing it is inclineddownwardly (the angle of inclination being somewhat.'v exaggerated onthe drawing for the purpose of illustration) and passes beneath suitablemeans for applying to the succession of elements carried by the conveyorheated asphalt in sufiicient quantity to coat completelythe exposedsurfaces and edges of the elements with a continuous film of asphalt.and means for showering the freshly coated surfaces with comminutedmineral such as crushed slate or the like. In order to apply an evencoating to the exposed surfaces of the elements, I may provide asuitable receptacle 24 4for molten asphalt. this receptacle havingtherein'heating units 25 ifdesired. One side edge of the receptacle 24is preferably cut'lower asat 26 than the other edges, a feeding guideI27 being secured thereto in order to feed a sheet lof molten asphaltfrom the receptacle 24 down to close proximity to the surfaces to becoated, this guiding means 27 being used to prevent the sheet frombreaking up into driblets under the action of surface tension, and thusto insure. an

'box 28 or other heating means may be provided in juxtaposition thereto,this heating means being available to regulate the temperature andhence'the viscosity of the as.- phalt at the moment it is deposited onthe elements 20. Immediately following the asphalt container 24 may belocated a suitable phalt.

opper 29 from which a shower of grit or other comminuted material may becontinuously de osited upon the freshly applied coating o asphalt bymechanism well known in the art. If desired, such surfacing material maybe heated as. by suitable units 30,

placed within the hopper to insure firmer engagement of the gritparticles with the as- The elements thus coated and surfaced on theconveyor 23 may then be separated and transferred to another conveyor31. In order to separate the elements, I may provide a roll 32 adjacentto the delivery end of the conveyor 23, the roll 32 being resiliently`supported to press on the successive elements. This roll is preferablydriven at a peripheral speed equal to thatl of the conveyor 23. Anotherroll 33 may be yieldingly supported to engage the elements at a pointadjacent to the receiving end of the conveyor 31, this roll and theconveyor 31 being preferably driven at an equal peripheral speed greater'than that of the roll 32 and the conveyor 23. The rolls 32 and 33 maybe so spaced that when the butt edge of a roofing element enters the nipbetween the roll 33 and the conveyor 31, the upper or head edge of thatelement will have cleared the roll 32. The next following element,however, which overlies the element entering the nip of the roll. 33 isatthis point still between the slower moving roll 32 and conveyor 23, sothat the faster feeding action of the roll 33 and conveyor 21 pulls theelement entering the nip between them away from the series on theconveyor 23 and thus spaces them as indicated in Figure 1. The rolls|32and 33 in addition to separating the successive elements also serve topressthe grit lying on the fresh coating on the faces of the elementsinto more intimate embedded contact with the asphalt. The elements onthe conveyor 31 may then be discharged edgewise one after the other to asuitable conveyor 34, guiding plates 35, 36 being provided'as desiredfor insuring the proper upright positionin of each element on theconveyor 34.` Suita le means may be provided for` shaping and finishingthe additional coating and surfacing layers which have been .applied tothe face and ed es of the butt portlon of the elements. Suc apparatusmay be as illustrated in Figures 1" and 2, and may comprise a pair ofvertically arranged endless belts 37, 38 between which the elements arede osite'd from the conveyor 31. These belts 3%, 38 are preferablyarranged t'o converge so that at their delivery end, the butt portion ofeachI element is pressed between their opposing faces as they passbetween the rolls 39, 40 which are preferably yieldingly mounted 'andadjustable both as-to axial direction and distance apart. At the sametime, the weight of the element on the conveyor 34 serves yto press thegrit adhering to the butt vedges ofthe element into more intimatecontact with the coating on the edges. If desired, the axes of the rolls39, 40 may be inclined toward each other slightly so that the pressingfaces of the belts 37, 38 which pass bet-Ween them will alsoconvergeupwardly. This tends to impart a taper to the thickened buttportion ,of the roofing element as indicated at 41 in Figure 6. In thisfigure .also are shown narrow tongues of asphalt and grit extendin up`-wardly from the butt portion, these lfbeing occasioned by the slots inthe element which overlapped this one in the series during theapplication of the asphalt and grit. f Slotted elements are shown in thedrawing merely by way of example, such' elements having a shape widelyused in the trade. It is obvious that the process and apparatus are notlimited to such a shape, and that if the slots were eliminated orreplaced by grooves or the like, the additional coating applied by thepresent method and apparatus would be limited substantially to theportion of the face and edges to be exposed to the weather when theelement is in position on a roof.

Ay modified form ofthe apparatus as a whole is illustrated in Figures 7to 12. As-

vcordingto this embodiment of the invention,

the conveyor 21 feeds to the conveyor 23 a series of roofing elementsoverlapped in the opposite direction to that shown in Figure 1, that is,the elements are fed head first instead of butt first, with the headportions thereof overlapped by the next element ahead, rather than bythe next following. In this case, I prefer to slope the conveyor 23upwardly so that the asphalt when applied as illustrated in Figure 9will tend to iow t0- ward the butt edges of each element. It is obvious,however, that if desired, the conveyor 23 may be level either in theform of apparatus shown in Figure 1 or that'shown in Figure 7 .n Thecoating device in the apparatus .illustrated in Figure 7 may beidentical with that illustrated `in Figure 1. The grit-applying device29 may 'also be the same, as well as the rolls 32 and 33 which separatethe overlapped shingles from one another. The separated shingles aredischarged head first on a conveyor 34 which carries at right angles totheir motion on the coning said elements 1n a series 1n successive yVeyors 23 and 31, as shown in Figure 8. overlappedv relatlon, conveyingthe over- Since in this case the butt portions of the elelapped elementslengthwise of the series past ments are uppermost as the shingles arecona given pomt, and flowing on sa1d series of veyed edgewise on theconveyor 34, the belts elements at said po1nt a continuous stream 37, 38and the` rolls 39, 40 about which the of molten asphalt extendingtransversely belts pass are elevated suiliciently to engage across theserles.

the butt portions of the elements passing axes of the rolls 39, 40 maybe inclined so as v rai'iging a series of elements in successive l todiverge upwardly and to tend to taper the overlapped relation such thateach element thickened butt portions of the elements which is lapped andsubstantially covered by adpass between them.l The butt. edges of .thejacent elements except for the face portion elements may at the sametimebe shaped as and edges to be exposed to the weather when desired. Asindicated in Figures 11 and 12, the' element is laid on a roof, flowinga a suitable roller 49 may be mounted to press continuous "stream ofwaterproofing material its edge against the butt edge of elements ontothe uncovered portions of the elements,

passing between the rolls 39, 40. As shown surfacingsaid coating withcomminuted main Figure '12, the roll 49 may have a grooved terial, andseparating the individual eleedge 50 to round olf the butt edge of theelements. y ments, but it is obvious that they may be 4. Ste sin themanufacture of roofing ele-A shaped in any desirable way by shaping thements, w ich comprise arranging a series of edge of the roll 49accordingly. elements in successive overlapping relation- The method ofthickening the butt portions ship, applying waterproof coating materialof roofing elements and sealing their butt to said elements while soarranged, surfacing edges as herein described is a simple and efthecoated portions with comminuted mafective way of applying the secondcoatmg `terial, separating the individual elements, of asphalt andsurfacin with grit to the exand thereafLr applying pressure to saidsurposed faces and edges o the roofing elements faced portions. v whichreadily lends itself to the apparatus 5. Steps in the method of makingthickdescribed. By this means and method, the butt roofing elements,which comprise arextra asphalt and grit are applied only to ran 'ng aseries of elements in successive those portions of the shingle w ichneed adover apped relation such that each yelement ditional protectivecoating, and the second is lapped and substantially covered by adcoatingof asphalt is made. to envelop the jacent elements except for the faceportion cut edges of the element at its butt portion and edges to beexposed to the weather when and to join the original asphalt coating, iilaid on a roof, applying a continuous coating there be one, on the underface .of the element #of molten asphalt to the uncovered portions toseal the edges of the butt portion and to of the elements, covering saidasphalt coat form a complete envelope enclosing the entire while hot andsticky with granular material, portion of the shingle which is exposedto separating the individual elements', and the weather when laid.pressing the coated face and edges of each Having thus described certainembodielement. ments of this invention, it should be evident 6. Steps inthe method of making thickto4 those skilled in the art that various buttroofing elements, which comprise archanges and modifications may be maderanging elements cut to shape from sheet therein without departing fromits spirit or roofing material of felted brous stock satuscope asdefined by the appended claims. rated and coated with asphalt andsurfaced I claim with granular mineral matter in an overl. The method ofcoating the face portion lapping series such that each element is subandedges of roofing elements, which are to stantially lapped and covered byadjacent be ex sed to the weather when t-he elements elements except forthe portion of its face are laid on a roof, which comprises arrangingand edges to be exposed to the weather when the lelements in a serieswherein the elements the element is laid on a roof, feeding the are insuccessive overlapped relation leaving elements such that thehead^portion of each only said face portion and edges of each eleelementis covered by the butt portion of anment unlapped, owing a continuousstream other element, applying progressively to the of coating onto theface and edges of the uncovered surfaces a continuous coating ofunlapped 'parts of said series of overlapped molten asphalt, showeringgranular mineral elements, and separating the individual elematter onsaid coating while still hot and ments from the series. sticky,separating the individual elements 2. The method of coating the faceportion successively from the series, and pressing the and edges ofrooiing elements, which-are to freshly coated surfaces of the elements.

be exposed to the weather when the elements 7. Apparatus of the classdescribed, com- 3. Steps in the method of making thick-l ftherebeneath.As'indicated in Figure 12, the butt roofing elements, which comprisearthem olf are laid on a roof, which comprises arran prising means forapplying a continuous film of molten asphalt to the exposed face andsignature.'

edge portions of a series of lapped roofing elements, means forsurfacing said film with granular mineral matter, means for thereafterseparating said elements successively from the series, and means forpressing said face and edge portions.

8. Apparatus of the class described, com-y prising means for conveying aseries of roofing elements in overlappin relationship, means forapplying a continuous film of molten asphalt'to the exposed surfaces ofthe elements A1n said series, means for covering said film with grit,means for separating the elements successively from the series, andmeans for molding the butt portions of the separated elements includingthe butt edges.

9. The method of coating a roofing eleyment, which comprises covering alportion of a face of a roofing blank with another roofing blank,covering the remaining portion of the f ace and adjacent edges with acoating of llqueiied asphalt, and separating said blanks. In testimonywhereof I have affixed my HAROLD L. LEVIN.

